3D scanning, reverse engineering of metallurgical equipment
CASE: The steel plant did not have detailed drawings for ordering packaged equipment.
RISKS: Ordering individual parts according to assembly drawings was impossible or very risky in terms of quality.
SOLUTION: DRT GROUP specialists performed 3D scanning, reverse engineering and equipment supply.
RESULT:
- in the process, mistakes in existing documentation were corrected, the previous supplier provided incorrect assembly drawings
- identified the reasons for the failure of the work rolls bearings
- a technical solution was proposed that simplifies the operation of the equipment
The project payback period is 2 months.
As part of the procurement procedures for metallurgical equipment and its spare parts, DRT GROUP provides reverse engineering services, examining the customer's equipment and documentation available in order to produce and supply an equivalent or modified solution.
To develop 3D models and working drawings of studied equipment, DRT GROUP arranges a visit to the customer's site, evaluates the current state of the equipment and the available documentation. Next, a detailed measurement of the equipment is carried out using the 3D scanning method. Particularly precise surfaces of large parts are additionally measured with a high-precision LEICA laser tracker.
An example of work on scanning the work rolls chocks of a cold-strip rolling mill. In this case, a portable 3D arm scanner was used. For larger equipment, a scanning measuring machine is used.
The scan result is a point cloud, on the basis of which an experienced design engineer will create a 3D model part. In the new project, tolerances and fits are assigned taking into account the wear of the measured surfaces, as well as based on existing experience and an extensive base of references.
For high-tech and critical parts, the following are performed:
- analysis of the chemical composition and determination of the material grade
- metallographic study to determine the method of production and heat treatment
- definition of face-hardening method
After measuring the customer's equipment and collecting all the necessary data, DRT GROUP engineers generate 3D models of all parts and a 3D general assembly model of the equipment, which allows to check the assembly of parts, the absence of overlaps, and also make an assembly drawing and specification for the designed piece of equipment based on this model.
Example of an assembly drawing made as part of a project for reverse engineering and supply of work roll chocks of a cold strip mill.
Currently (2023), DRT GROUP is carrying out 3 reverse engineering and supply projects: work and back-up roll chocks assemblies for the four-stand cold-strip rolling mill, as well as back-up roll chocks assemblies for the five-stand cold-strip mill.
An example of the DRT GROUP competence on the case of a project for the reverse engineering of assembled work roll chocks: the customer had old drawings for some parts, but there were doubts about their relevance, since the original supplier made several changes to the design over 30 years of exclusive supplies and did not provide an updated documentation. In addition to showing in the new drawings the actual design of all the parts included in the chock assemblies, DRT GROUP engineers modified the design of the upper work roll chock bodies. One body can now be used for both operator and drive side installations, reducing bodies inventory and optimizing budget accordingly. The material of chock bodies has been improved in accordance with advanced solutions for similar mills. Standard components have been updated and unified. A design issue has been identified that resulted in a short service life of the work roll bearings currently observed in the mill - apparently to simplify the assembly of the chocks, the covers produced by the factory repair shop fit into the chock body with a large gap, as a result of which they are not properly centered and this leads to the rapid wear of the seals and the ingress of the emulsion into the bearing, significantly worsening the antifriction properties of the oil, as well as precipitating in the roll grooves, thereby causing overheating and early failure of the bearing. In the new project, the design of the covers has been modified to ensure proper centering.